System and method for real-time activity-based accounting

ABSTRACT

An accounting method and system is disclosed that provides for real time financial accounting of plant performance at a sub-plant level. A multiplicity of process variable transmitters is utilized to sense, in real time, the current state of the processes and process equipment used in a manufacturing plant. Sub-plant accounting modules utilize the sensed process data to calculate a plurality of sub-plant accounting measures, which are stored in one or more real time plant historian. The accounting measures are typically converted to a suitable format and subsequently stored in a production model accounting database where they are accessible to an accounting module.

RELATED APPLICATION

This application is a Continuation of U.S. patent application Ser. No.10/120,992 entitled A System And Method For Real-Time Activity-BasedAccounting, filed on Apr. 11, 2002 now U.S. Pat. No. 7,685,029, whichclaims the benefit of U.S. Provisional Application Ser. No. 60/351,598,entitled A System and Method for Real-Time Activity-Based Accounting,filed Jan. 25, 2002.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally to accounting systems and/orenterprise resource planning (ERP) systems. This invention moreparticularly relates to a sensor based accounting system for providingreal-time, activity based accounting for both unit and plant wideoperations in a manufacturing plant.

(2) Background Information

Conventional cost accounting systems are typically inadequate asdecision support systems or as a tool for the measurement and/oranalysis of manufacturing performance. Most conventional cost accountingsystems were designed as fiduciary reporting systems, which typicallyrequire monthly and/or quarterly reporting, rather than as decisioncontrol systems, which typically require real-time and daily feedback.Therefore, the information collected and reported does not tend tosupport minute-to-minute and/or day-to-day operational activities.Furthermore, the resolution of a conventional cost accounting systemtends to be limited to plant level analysis. For example, a conventionalcost accounting system records the total number or amount of product(s)made in a given unit of time (e.g., monthly) and divides that number oramount by the total costs (e.g., total energy consumption plus the totalmaterial costs plus fixed overhead costs) to arrive at a price per unitor price per unit volume. It therefore tends to be difficult to obtainaccurate economic information on a unit operation or plant area level.These limitations tend to be acutely realized during cost benefitanalysis of various process improvement activities. Senior managementgenerally looks to a finance and/or accounting function for confirmation(especially as it relates to costs) of process improvements.Unfortunately, as described above, conventional accounting systems lackthe information required (both at a unit operation level and temporally)to provide confirmation.

The limitations of conventional accounting systems have been addressedin part by Ebling, et al., in U.S. Pat. No. 4,864,507 entitled “Methodand Apparatus for Process Manufacture Control”, which is hereinafterreferred to as the Ebling patent and which is fully incorporated byreference herein. The Ebling patent discloses a digital data processingapparatus for manufacturing process control having a production-modelingelement for generating and storing a production model representative ofvarious manufacturing relations. The production models may be configuredto define the significant sub-plant components, such as the unitoperations and plant areas, and to provide accounting information bythese components. MARCAM® Corporation (Needham, Mass.) has successfullymarketed this approach in both its PRISM® and PROTEAN® softwarepackages, which are widely considered to be an improvement overconventional accounting systems, particularly for relatively complexoperations, such as a specialty chemical plant in which a wide varietyof resources are consumed in the production of a broad line of products,and/or wherein complex interrelationships exist between various unitoperations. Nevertheless, despite its advantages and relativelysuccessful commercial sales over the past decade, this approach remainslimited in that it typically requires plant level costs, such asutilities, to be allocated (based on an arbitrary mechanism to thepredetermined production model as described hereinabove) to eachsub-plant component. This approach tends to limit the usefulness of suchaccounting systems since at the sub-plant level it only provides anestimate (based on the production model) of the actual accountinginformation. This approach is further limited as a decision supportsystem (e.g., for critically evaluating process improvement measures)since the estimates tend to reinforce the production model assumptionsrather than providing independently measured accounting data.

An alternate approach has been disclosed by Beaverstock, et al., in U.S.Pat. No. 5,134,574, entitled “Performance Control Apparatus and Methodin a Processing Plant”, which is hereinafter referred to as theBeaverstock patent and which is fully incorporated by reference herein.The approach of the Beaverstock patent is advantageous in that itdiscloses a sensor-based control apparatus for providing near real-timeindication of the performance of plant operations. These dynamicperformance measures (DPMs) are typically engineering measurements suchas quality, yield, downtime, production volume, and/or production costand may further be used to supplement conventional process controlmethodologies. Nevertheless, despite this advancement, the apparatusdescribed in the Beaverstock patent tends to be limited in that it maybe essentially thought of as an engineering tool for optimizingmanufacturing processes. As such it does not provide for even therudimentary accounting requirements of a plant, such as an accounting ofprofit and loss (at either a plant or sub-plant level). Furthermore, andpartly as a result of the above, the dynamic performance measures(particularly those expressed as costs) tend to lack credibility withsenior management and those in the accounting and/or financialfunctional areas of a business.

Therefore, there exists a need for an accounting system that overcomesthe limitations of the systems described hereinabove and that providesnear real time accounting measures at both plant and sub-plant (e.g.,unit operations) levels and for near real time decision support for boththe engineering and accounting functions of a manufacturing plant.

SUMMARY OF THE INVENTION

One aspect of the present invention includes a real-time activity basedaccounting system for a manufacturing plant having at least onemanufacturing process. The accounting system includes at least onesub-plant accounting module configurable to receive process data fromone or more sensors associated with the manufacturing process. Thesub-plant accounting module includes computer readable program code forcalculating one or more sub-plant accounting measures using the processdata. A process historian is coupled to at least one of the sub-plantaccounting modules. A translation module is coupled to the processhistorian. A production model accounting database is configured toreceive the accounting measures from said translation module, and anaccounting port is operatively associated with the production modelaccounting database, for interfacing with an accounting module.

Another aspect of the invention includes a real-time activity basedaccounting system for a manufacturing plant having at least onemanufacturing process. The accounting system includes a multiplicity ofprocess variable transmitters coupled to a plurality of processequipment in a manufacturing plant for providing signals indicative ofthe states of the manufacturing process and a plurality of sub-plantaccounting modules configured to receive process data from one or moreof the process variable transmitters, the sub-plant accounting modulesincluding computer readable program code for calculating one or moresub-plant accounting measures from the process data. The accountingsystem further includes a process historian module, coupled to at leastone of the plurality of sub-plant accounting modules, a translationmodule coupled to the process historian, the translation moduleincluding computer readable program code for formatting the sub-plantaccounting measures stored in the process historian module into asuitable format, a production model accounting database configured forreceiving, storing and partitioning accounting measures from thetranslation module, and an accounting module coupled to the productionmodel accounting database, the accounting module configured to provideaccounting and reporting functionality.

In another aspect, this invention includes a method for providingreal-time, sensor-based accounting in a manufacturing plant. The methodincludes capturing process data with a multiplicity of process variabletransmitters, the process variable transmitters being coupled to processequipment in the manufacturing plant. The method further includescomputing a plurality of real-time, sub-plant accounting measures fromthe process data, and storing the real-time, sub-plant accountingmeasures in a process historian. The sub-plant accounting measures areconverted into a format useful for an accounting system, and loaded intoa production model accounting database. Sub-plant and plant levelaccounting functions are selectively performed on the accountingmeasures loaded in the production model accounting database to acquirean accounting analysis. Results are then displaying.

In yet another aspect, this invention includes a method for implementinga real-time activity based accounting system for a manufacturing planthaving a plurality of manufacturing processes. The method includesanalyzing plant production flow and manufacturing strategy, determiningplant accounting requirements and required sub-plant accountingmeasures, and installing process variable transmitters. The methodfurther includes building a plurality of sub-plant accounting modules,each of the plurality of sub-plant accounting modules including computerreadable program code for receiving process data from at least one ofthe process variable transmitters and using the process data to computeone or more sub-plant accounting measures, configuring a processhistorian to receive real-time sub-plant accounting measures from thesub-plant accounting modules, programming a translation modules forformatting the real-time sub-plant accounting measures into a formatsuitable for the accounting system, and structuring a production modelaccounting database to include a plurality of sections relating to saidplurality of manufacturing processes. An accounting module is configuredfor selectively performing sub-plant and plant level accounting analysisfrom sub-plant accounting measures stored in the production modelaccounting database.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of the accounting system of the presentinvention;

FIG. 2 is a block diagram of another embodiment of the accounting systemof this invention;

FIG. 3 is a block diagram of still another embodiment of the accountingsystem of this invention;

FIG. 4 is a block diagram of yet another embodiment of the accountingsystem of this invention; and

FIG. 5 is a flow chart of a method for implementing the accountingsystems of FIGS. 1-4 in a typical manufacturing plant environment.

DETAILED DESCRIPTION

A manufacturing or process plant employs various and numerous items ofequipment to implement different functions or effects on sourcematerials to form desired finished products. The different pieces ofequipment or groups thereof are generally referred to herein as processequipment. Examples of process equipment include vats, mixers, heatingunits, conveyer belts, pumps, evaporators, filters, boilers, generators,reaction chambers, and the like. The functions provided by the differentpieces of equipment or groups thereof are generally referred to hereinas processes or unit operations. Examples of processes includeseparation, mixing, evaporating, distilling, extracting, crushing,welding, polishing, and the like. Multiple processes or unit operationsare often grouped together and referred to in the singular as a plantarea. Further, where used in this disclosure, the term computergenerally refers to any suitable processing device including, aprogrammable digital computer, microprocessor, microcontroller, etc.,including dedicated, embedded, and general-purpose computers,programmable logic controllers (PLCs), workstations, and/or mainframes.

In general, the present invention includes a real-time, activity-basedaccounting system, typically for use in manufacturing and/or processingplants and may provide for real time (e g, minute-by-minute or day byday) financial accounting of plant performance at a sub-plant level(e.g., at a process equipment, unit operations, or plant area level).This invention generally employs real-time sensing of the current stateof the processes and process equipment used in the manufacturing plant.The sensed process data is utilized to calculate sub-plant accountingmeasures (e.g., material cost, utility cost, or production rate for asingle process), which are stored in one or more real-time planthistorians (e.g., database management systems). The real-time sub-plantaccounting measures are typically converted into a format suitable foran accounting system structured to provide both sub-plant and plant wideaccounting analysis.

Referring briefly to FIGS. 1-4, an accounting system 100 according tothe principles of the present invention is illustrated. System 100includes a multiplicity of process sensors 140 a, 140 b, 140 c, 140 d,140 e, 140 f (hereinafter referred to as 140 a-f) configured for realtime monitoring of process variables. In various embodiments, processsensors 140 a-f include conventional process variable transmitters(e.g., available from Invensys Systems, Inc., Foxboro, Mass.), whichcapture and transmit sensed process data. These sensors 140 a-f arelinked to a plurality of sub-plant accounting modules 130 a, 130 b, 130c (hereinafter referred to as 130 a-c), which convert the process datainto sub-plant accounting measures (e.g., material costs at a unitoperation level). The sub-plant accounting modules 130 a-c are linked toat least one process historian 120, which stores the sub-plantaccounting measures, and which is further linked (e.g., through atranslation module 125 and production model database 115) to a plantaccounting module 110, configured to provide standard accounting andreporting functionality. Translation module 125 formats the sub-plantaccounting measures generated by sub-plant accounting modules 130 a-cinto a form suitable for plant accounting module 110. Production modeldatabase 115 is configured according to the particular process flow andaccounting needs for the plant, and will be described in greater detailhereinbelow.

The present invention is advantageous in that it provides for bothtraditional plant accounting functions as well as a real time financialaccounting of plant performance at a sub-plant level. This invention isfurther advantageous in that it provides for strategic decision supportbased on sensor based financial measures at both the plant and sub-plantlevels. Further, this invention provides for financial analysis of plantand sub-plant performance and performance improvement measures in realtime (e.g., hourly or daily). This invention is yet further advantageousin that it may overcome the drawbacks of the prior art systems describedhereinabove. Other and still further advantages of this invention aredescribed hereinbelow in a discussion of various embodiments thereof.

Referring now to the Figures in greater detail, as shown in FIG. 1,accounting system 100 (as well as systems 100′, 100″, and 100′″ of FIGS.2-4) includes a multiplicity of sensors 140 a-f configured for real-timemonitoring of process variables. Specifically, each sensor 140 a-ftypically provides signals indicative of the current state of one aspectof a particular process within a manufacturing plant. Depending upon thecomplexity of the manufacturing operation and upon the resolution ofaccounting data required to satisfy strategic objectives, system 100 mayinclude any number of sensors 140 a-f, typically ranging from a few fora relatively simple process to many hundreds or even thousands for amore complex process, such as an oil refinery. The sensors 140 a-f mayinclude substantially any type of device capable of sensing orgenerating data of interest such as but not limited to temperature,pressure, flow rate, velocity, volume, weight, pressure, voltage, andcurrent sensors; analytical measurement devices, timers, counters,meters, control elements such as valves and switches, and/or other datalogging devices. One example of a sensor 140 a-f, including a processvariable transmitter, includes a conventional mass flow meter formeasuring the mass of fluid flowing through a conduit, such as an 83Series Vortex™ flowmeter available from Invensys Systems, Inc.

Accounting system 100 further includes a plurality of sub-plantaccounting modules 130 a-c, each of which is configured to receiveprocess data from one or more sensors and to calculate direct real-timesub-plant accounting measures therefrom. For example, in one embodiment,a sub-plant accounting module 130 a-c includes an algorithm forconverting flow rate data from a mass flow meter into feedstock cost fora single unit operation. Alternatively, another sub-plant accountingmodule 130 a-c may include an algorithm for converting flow rate datafrom a mass flow meter into a production rate. Each sub-plant accountingmodule 130 a-c thus provides an accounting measure (i.e., accountingdata) for a particular aspect of the manufacturing process. System 100may include any number of sub-plant accounting modules 130 a-c, asdescribed hereinabove with respect to sensors 140 a-f, typically rangingfrom a few for a relatively simple process to many hundreds or eventhousands for a more complex process.

Each sub-plant accounting module 130 a-c includes computer readableprogram code for computing sub-plant accounting measures from real-time,sensor-based process data. Modules 130 a-c are typically programmedusing object oriented programming techniques known to those skilled inthe art. For example, in one embodiment, the sensor-based process datais represented by input blocks, which are input into modules 130 a-c byspecifying the input block parameter(s) (e.g., field or record) ofinterest. A preprogrammed algorithm block may then perform computationson the obtained input data as directed by predetermined mathematicalrelationships. The output of modules 130 a-c is typically stored ineither a local or global historian 120 as described in more detailhereinbelow. The sub-plant accounting modules 130 a-c are configured toexecute (i.e., read the inputs from the input blocks and generate outputblocks for storage in historian 120) at a predetermined frequency. Thisfrequency of execution is dependent on the manufacturing process,process equipment, and the process sensors 140 a-f, as well as on theoperational strategies of the particular plant, but typically rangesfrom about ten per second to about one per minute. In one embodiment,each accounting module 130 a-c includes e.g., a JAVA® (Sun Microsystems,Inc., Palo Alto, Calif.) application (or applet) that implements thereceiving of the input block, calculation of the accounting measure(s),and the storing thereof into an output block (which may be accessed byhistorian 120) at a predetermined interval.

By way of example, and not limitation, an accounting module 130 a-cuseful in a power plant, such as may be found in any major industrialmanufacturing operation, is considered. For instance, the objective of apower plant is to provide energy in its various forms to the variousprocessing areas within the plant for operating a manufacturing process.For the purposes of this example, it is assumed that the power plantconsists of two boilers and a generator. Steam from the two boilers isused both to drive the generator, which in turn, provides electricityfor the plant, and to provide steam directly to a number of processunits in the plant. The plant can also purchase electricity from a localutility and can sell excess electricity to the utility.

Efficient operation of this power plant requires ongoing decisions onthe sourcing of plant steam and electricity. These decisions should bebased on the best balance of costs and profits around the steam andelectric generation and the market price of electricity sold through theexternal power grid. Making these decisions correctly and on the righttime frame requires more information about the power operation availableat a faster rate than has traditionally been available through eitherinformation management systems (e.g., enterprise resource planning (ERP)systems) or plant automation systems. According to the principles ofthis invention (and as described in more detail hereinbelow with respectto FIG. 5), one of the first steps in providing the required informationinvolves a top down analysis of the manufacturing plant strategy todetermine the necessary sub-plant accounting measures. For the purposesof this example it is assumed that the analysis identifies the cost ofenergy for each boiler, the cost of water to each boiler, the cost ofsteam for the generator, the value of electricity produced, and the spotprice of electricity on the external grid. Each of these data points(with the exception of the spot price of electricity on the externalgrid) may be modeled in real time using sensor-based process data fromthe power plant. The power plant will employ numerous sensors, includingmass flow meters for measuring the flow of water and steam, and loadcells for measuring the quantity of fuel (e.g., coal) consumed in eachof the boilers.

For the purposes of this example a real time accounting measure for thecost of steam to the generator may be calculated using Eq. 1 as follows:(percentage of steam to the generator from boiler #1)×[(incremental coalconsumed×value of the coal)+(incremental water consumed in boiler#1×value of the water)]+(percentage of steam to the generator fromboiler #2)×[(incremental gas consumed×value of the gas)+(incrementalwater consumed in boiler #2×value of the water)]  Eq. 1

It is appreciated that there are many possible approaches to thedevelopment of modules 130 a-c of the present invention. It is alsounderstood that one of ordinary skill in the art is familiar with thepertinent subroutines for running addition, subtraction, multiplication,division, averaging, percentage calculations, and the like.

As mentioned hereinabove, process historian module 120 is configured forstoring the real-time sub-plant accounting measures. Historian module120 is implemented in any suitable electronic data storage device, maybe implemented in a computer, such as a personal computer (e.g., asavailable from Dell Computer Corporation, Round Rock, Tex.),workstation, or may include a dedicated machine such as an I/A Series™historian or Aim* AT™ historian available from Invensys Systems, Inc.,depending on the storage and analysis requirements thereof and theflexibility requirements of the user(s). Process historian 120 mayinclude any suitable data storage module, including a commercialdatabase, such as MICROSOFT® Access (Microsoft Corporation, Redmond,Wash.). However, process historian 120 may also include a customdatabase package suitable for relatively high speed and high volumestorage of real-time data as is typically required in a manufacturingplant. In an exemplary embodiment, historian 120 includes a JAVA® appletthat receives data from output blocks generated by accounting modules130 a-c, using SQL (Structured Query Language) and a JDBC (JAVA®Database Connectivity) to ODBC (Open Database Connectivity) bridge. Thedata is then stored in the database in the ODBC format. Historian 120may be programmed to update at substantially any interval, but typicallyupdates at least several times per day.

As also mentioned hereinabove, translation module 125 converts the rawsub-plant accounting measures data from historian 120 into a formsuitable for plant accounting module 110 and/or production model 115(described in more detail hereinbelow). For example, in order toreconcile the relatively high frequency operation of the real-timeaccounting measures 130 a-c with the relatively lower frequencyoperation of a plant accounting module, averages and/or totals may becalculated at predetermined intervals. Translation module 125 typicallyutilizes data reduction techniques operating on a periodic basis tocalculate the average, standard deviation, maximum, minimum, and/ortotal values over the specified period. For example, translation module125 may compute hourly averages and/or totals from the real-time (e.g.,per minute) sub-plant accounting measures calculated at modules 130 a-cand stored in historian 120. The sub-plant accounting measures may alsobe reduced (e.g., averaged or totaled) at other intervals of interest,such as shift, daily, weekly, monthly, quarterly, and the like. Thesetranslated values are then typically stored within the historian 120 orin a separate database (or object) within translation module 125. In oneembodiment, translation module 125 includes JAVA® applets configured toperform basic mathematical operations on the sub-plant accountingmeasures, such as calculating the average or the total in apredetermined time interval. Alternatively, translation module 125 mayinclude one or more macros programmed using conventional subroutines(e.g., averaging subroutines).

As also described above, accounting system 100 includes a productionmodel accounting database 115 linked to translation module 125.Production model accounting database 115 includes a database module,e.g., a commercially available database such as a MICROSOFT® SQL ServerORACLE® Enterprise Server (Oracle Corporation, Redwood Shores, Calif.),or IBM® DB2 (International Business Machines Corporation, Armonk, N.Y.),configured according to the production flow and accounting needs of aparticular manufacturing plant. Typically, database 115 is a relationaldatabase having a predefined schema and is structured for enabling bothgeneral ledger accounting at plant level (such as is typically requiredby plant accounting and/or financial groups, and discussed below withrespect to accounting module 110) and sub-plant accounting of variousprocesses, process equipment, and/or plant areas. Production modelaccounting database 115 may be setup in any number of ways dependingupon the particular process equipment being used and the manufacturingstrategies of the plant. Typically the various process equipment, unitoperations, and plant areas are defined in database 115 to enable thedirect reporting of measures through translation module 125.

By way of illustration, and not limitation, in the power plant exampledescribed hereinabove, database 115 includes a power plant definition,which includes fields for storing accounting measures related thereto(e.g., the cost of energy for each boiler, the cost of water to eachboiler, the cost of steam for the generator, and the value ofelectricity produced). As described above, data pertaining to thesemeasures are stored in historian 120 (or translation module 125). Thesedata may then be communicated to database 115 at a predeterminedinterval (the translation module 125 may ‘push’ data to database 115 ordatabase 115 may ‘pull’ data from translation module 125). For example,accounting database 115 may issue standard database calls (e.g., in OpenDatabase Connectivity (ODBC), Oley Process Control (OPC), or XMLprotocols) at predetermined intervals (e.g., shift, daily, weekly,monthly, etc.). Alternatively, for embodiments of historian 120 ortranslation module 125 that do not support standard database protocols,accounting database 115 may be provided with a software application,such as a JAVA® applet, configured to import the appropriate data fromhistorian 120. For example, translation module 125 may be configured toexport data into a flat file, which is then imported into database 115.An import program may be used to insert the data in the proper locationin database 115 based on program code that maps the fields from theimport file to the appropriate fields in database 115.

Accounting system 100 further includes an accounting module 110 linkedto production model accounting database 115. Accounting module 110includes a software module providing standard accounting and reportingfunctionality (e.g., general ledger type functionality). The combinationof accounting module 110 and accounting database 115 provides for bothplant and sub-plant level accounting analysis at substantially any timeinterval (e g, minute-by-minute, day-by-day, and/or month-by-month). Astransactions, such as usage, consumption, and production are measuredvia accounting measures 130 a-c, journal entries are generated forposting to accounting module 110 so that appropriate accounts aredebited and credited. Module 110 is configured to retrieve theappropriate data from accounting database 115 and make the requiredcomputations. Module 110 is typically further configured for reportingaccounting analysis in one or more suitable formats (e.g., printedreports and/or on-line readable reports). Module 110 may be acommercially available accounting software package, such as thoseavailable from BAAN® Solutions (Baan Development, Netherlands), SAP®(SAP Artiengesellschaft, Federal Republic of Germany), and JDE® (J. D.Edwards & Company, Denver, Colo.) running on a suitable platform. Theaccounting system 100 of the present invention is typically implementedin a computer network, such as a local area network (LAN) including arelatively large number of computers. For example, in one embodiment100′ shown in FIG. 2, which is typically desirable for relativelycomplex manufacturing processes, a plant business computer 112 (orcomputer system) including accounting module 110 and production modelaccounting database 115 is linked to one or more process and/or plantarea supervision computers 122, each of which includes a processhistorian 120 and a translation module 125. The process supervisioncomputer(s) 122 are further linked to a plurality of process controlcomputers 132 a-c, each of which includes one or more sub-plantaccounting modules 130 a-c. Although FIG. 2 shows a single sub-plantaccounting module 130 a-c per process control computer 132 a-c, theartisan of ordinary skill will readily recognize that a single processcontrol computer 132 a-c may also include two or more sub-plantaccounting modules 130 a-c. For example, in an alternate embodiment, asingle process control computer 132 a-c may be used for a single unitoperation and include two or more sub-plant accounting modules 130 a-c(e.g., one for utility costs, one for feedstock cost, and another forproduction rate).

Computers 112, 122, and 132 a-c and process sensors 140 a-f aretypically linked using local area network (LAN) or other commerciallyavailable network connections configured to enable nominally anycomputer in the network having requisite permissions to obtain sub-plantaccounting data from any other. Computers 112, 122, and 132 a-c andprocess sensors 140 a-f may also be linked using substantially any othernetworking protocol and hardware, such as a hardwired telephone line, acellular telephone link, a fieldbus, an Ethernet or fast Ethernetinterface, a LOCALTALK® connection, a satellite or other wirelessconnection, a commercial radio frequency (RF) communication link, aninfrared communication link, or the like, including enhancements oralternatives thereto that may be developed in the future. Further,computers 112, 122, and 132 a-c and sensors 140 a-f may be configuredfor enabling a user to remotely connect thereto (e.g., direct dial-upusing a modem) to obtain status, diagnostics, or other deviceinformation.

For relatively small and/or less complicated manufacturing plants (e.g.,a typical food processing plant), system 100 may be implemented in asingle computer as shown in embodiment 100″ in FIG. 3. For example,accounting system 100″ includes a single computer 114 (including modules110, 115, 120, 125, and 130 a-c) linked to a multiplicity of sensors 140a-f. Alternatively, system 100 may be implemented in two or morecomputers as shown in embodiment 100′″ in FIG. 4. For example, system100′″ includes a plant business computer 112, including an accountingmodule 110 and a production model accounting database, linked to a plantarea supervision computer 124, which includes process historian 120,translation module 125 and a plurality of sub-plant accounting modules130 a-c, and is linked to a multiplicity of sensors 140 a-f.

Additionally, each computer, shown in FIGS. 2-4, may include one or moregraphical user interface (GUI) having various function menus and/oricons, which may be actuated by a user to effect various functions knownto those skilled in the art of GUIs.

Referring now to FIG. 5, one embodiment of a method 200 for implementingthe accounting system 100 of the present invention is discussed. Theactual sub-plant accounting measures (e.g., calculated in modules 130a-c) required for a particular plant operation are a function of boththe functional layout of the plant processes and the manufacturingand/or accounting strategies. The sub-plant accounting measures that aremost appropriate for various unit operations or groups thereof in oneplant may not be appropriate at all for another plant (even for anotherplant of a similar type). Therefore, prior to the physical installationof the accounting system 100 of this invention, this method includesoptional portions 202, 204, and 206. These optional portions includeanalyzing both the production flow 202 and the plant manufacturingstrategy 204, from which plant accounting requirements 206 and thenecessary sub-plant accounting measures 208 may be determined (blocks202, 204, and 206 shown in phantom in FIG. 5). By way of example (andnot limitation) a manufacturing plant with a strategy of reducing costsmay require a relatively high degree of detail regarding utilization ofraw materials and energy through the plant. This plant may thereforerequire a relatively large number of sub-plant accounting modules 130a-c to accurately track real time raw material and energy consumption atthe processes. Alternatively, a manufacturing plant with a principlestrategy of increasing throughput may require a relatively high degreeof detail regarding rate of output at each of the unit operations andmay therefore require a relatively large number of sub-plant accountingmodules 130 a-c pertaining thereto.

Once the specific sub-plant accounting measures have been determined,the sensor information required 210 to make the measures is determined.In many manufacturing plants the required sensors 140 a-f are alreadyinstalled in the process or with process equipment of interest. In somecases, new sensors need to be installed 212 to complete the collectionof sensor-based information required to compute the necessary sub-plantaccounting measures. Installation of the sensors includes connectingthem (e.g., via their process variable transmitters) to a network and/ordirectly to the appropriate sub-plant accounting modules. Installationmay further include constructing input blocks for each of the requiredsensor-based inputs. These blocks convert the incoming sensor signals(either analog or digital) into digital values in theengineering/economic units required for the calculation of the sub-plantaccounting measures. As discussed above, each input block typicallyincludes a collection of records or fields, each of which holdsparticular process data. The input block may also provide for generalsystem (or network) access to process data.

After determining the sub-plant accounting measures and implementing therequired sensors at steps 208 and 212, the sub-plant accounting modulesare built 214. As described hereinabove, the sub-plant accountingmodules 130 a-c are typically programmed using object orientedprogramming techniques known to those skilled in the art. For eachmodule 130 a-c, an algorithm block is typically programmed. Eachalgorithm block is programmed to request or otherwise obtain processdata from one or more specific input blocks, perform calculationsthereon as directed by the mathematical relationships set forth in thealgorithm block, and direct the output of the calculations to an outputblock.

A process historian 120 is configured 216 to receive the computedaccounting measures (e.g., from the above mentioned output blocks) asdescribed hereinabove. Translation routines (or translation blocks) areprogrammed at block 218. These routines may be programmed insubstantially any manner but are commonly programmed using either objectoriented programming techniques or by creating macros using subroutinesavailable in historian 120.

At block 220, a production model accounting database 115 is configured.Based on the prior analysis (e.g., generated at blocks 202, 204, 206,and 208), database 115 includes definitions representative of thevarious unit operations (or alternatively the plant areas or theequipment) in the plant. At block 222, accounting module 110 isconfigured to perform the desired accounting analysis and reportingutilizing data from predetermined partitions within database 115.

The modifications to the various aspects of the present inventiondescribed hereinabove are merely exemplary. It is understood that othermodifications to the illustrative embodiments will readily occur topersons with ordinary skill in the art. All such modifications andvariations are deemed to be within the scope and spirit of the presentinvention as defined by the accompanying claims.

What is claimed is:
 1. A real-time activity based accounting systemincluding a computer usable medium having computer readable codetherein, for a manufacturing plant having at least one manufacturingprocess, said accounting system comprising: a plurality of sub-plantaccounting modules configurable to receive process data from a pluralityof sensors associated with the manufacturing process; said sub-plantaccounting modules including computer usable medium having computerreadable program code therein for calculating a plurality of sub-plantaccounting measures using the process data of the plurality of mutuallydistinct process variables, for posting to an accounting module; aprocess historian coupled to said sub-plant accounting modules; atranslation module coupled to said process historian; the translationmodule configured to receive and aggregate the plurality of sub-plantaccounting measures; a production model accounting database having aplurality of sections configured for modeling the manufacturing processin the manufacturing plant; the production model accounting databaseconfigured to receive and selectively place the aggregated accountingmeasures from said translation module into said plurality of sections inreal-time; and an accounting port operatively associated with saidproduction model accounting database, said accounting port beingcouplable with the accounting module, wherein the accounting system isconfigured to supply real-time, aggregated data from the productionmodel accounting database to the accounting module; wherein theaccounting system is configured to move data along a hierarchicallyupward data path from the sensors, to the sub-plant accounting modules,to the production model accounting database, the accounting port, and tothe accounting module.
 2. The accounting system of claim 1, wherein saidtranslation module comprises a computer usable medium having computerreadable program code therein for formatting the sub-plant accountingmeasures stored in said process historian module.
 3. The accountingsystem of claim 1, wherein said production model accounting database isconfigured to receive, store and partition the accounting measures. 4.The accounting system of claim 1, comprising a plurality of sub-plantaccounting modules.
 5. The accounting system of claim 4 wherein each ofsaid plurality of sub-plant accounting modules comprises an algorithmblock for computing one or more sub-plant accounting measures from theprocess data.
 6. The accounting system of claim 1, comprising anaccounting module coupled to said accounting port.
 7. The accountingsystem of claim 6, wherein said accounting module is configured toprovide accounting and reporting functionality.
 8. The accounting systemof claim 6 wherein said sub-plant accounting module, said processhistorian module, said translation module, said production modelaccounting database, and said accounting module, are disposed within asingle computer.
 9. The accounting system of claim 8 wherein said singlecomputer comprises a member selected from the group including a personalcomputer and a workstation.
 10. The accounting system of claim 6wherein: said accounting module and said production model accountingdatabase are disposed in a first computer; and said process historian,said translation module and said sub-plant accounting module aredisposed in a second computer.
 11. The accounting system of claim 6wherein: said accounting module and said production model accountingdatabase are disposed in a first computer; said process historian andsaid translation module are disposed in a second computer; and aplurality of sub-plant accounting modules are disposed in a plurality ofother computers.
 12. The accounting system of claim 6, wherein saidaccounting module and said production model accounting database aredisposed in separate computers.
 13. The accounting system of claim 1configured to provide real-time accounting on a time scale ranging fromabout second-by-second to about year-by-year.
 14. The accounting systemof claim 13 configured to provide real-time accounting on a time scaleranging from about hour-by-hour to about month-by-month.
 15. Theaccounting system of claim 1, comprising a plurality of process variabletransmitters couplable between the sensors and said sub-plant accountingmodule.
 16. The accounting system of claim 15, comprising at least onesensor coupled to each of said process variable transmitters.
 17. Theaccounting system of claim 16 wherein said sensors comprise flow meters,weight sensors, volume sensors, velocity sensors, pressure sensors,temperatures sensors, analytical measurement devices, counters, voltagesensors, current sensors, meters, and timers.
 18. The accounting systemof claim 1 wherein said at least one manufacturing process comprisesprocess equipment selected from the group consisting of vats, mixers,heating units, conveyer belts, pumps, evaporators, filters, boilers,reaction chambers, generators, and combinations thereof.
 19. Theaccounting system of claim 1, comprising a graphical user interfaceconfigured to display accounting data generated by said accountingsystem.
 20. The accounting system of claim 1 wherein said plurality ofsub-plant accounting measures comprise a computer usable medium havingobject oriented computer readable program code embodied therein.
 21. Theaccounting system of claim 1 wherein said translation module isconfigured to selectively average and total the accounting measures atpredetermined intervals.
 22. The accounting system of claim 21 whereinsaid predetermined intervals are selected from the group consisting ofhourly, shift, daily, weekly, biweekly, monthly, bimonthly, quarterly,and combinations thereof.
 23. The accounting system of claim 1 whereinsaid production model accounting database comprises a plurality ofsections configured for modeling a plurality of manufacturing processesin the manufacturing plant.
 24. The accounting system of claim 23wherein said production model accounting database is configured to issuedatabase calls to said translation module at predetermined intervals toreceive said accounting measures.
 25. The accounting system of claim 24wherein said database calls comprise: pointers for locating accountingmeasures within said translation module; and information regarding intowhich of said plurality of sections said accounting measures are to bestored.
 26. The accounting system of claim 23 wherein said translationmodule is configured to insert said accounting measures into saidproduction model accounting database at predetermined intervals.
 27. Areal-time activity based accounting system for a manufacturing planthaving at least one manufacturing process, said accounting systemcomprising: a plurality of process variable transmitters coupled toprocess equipment in the manufacturing plant for providing process datafrom a plurality of sensors associated with the manufacturing process,the plurality of sensors configured to detect a plurality of mutuallydistinct process variables of the manufacturing process; a plurality ofsub-plant accounting modules configured to receive process data from oneor more of said process variable transmitters; said sub-plant accountingmodules including a computer usable medium having computer readableprogram code therein for calculating one or more sub-plant accountingmeasures from the process data of the plurality of mutually distinctprocess variables; a process historian module, coupled to at least oneof said plurality of sub-plant accounting modules; a translation modulecoupled to said process historian, said translation module including acomputer usable medium having computer readable program code therein forformatting the sub-plant accounting measures stored in said processhistorian module into a suitable format; the translation moduleconfigured to receive and aggregate the plurality of sub-plantaccounting measures; a production model accounting database having aplurality of sections configured for modeling the manufacturing processin the manufacturing plant; the production model accounting databaseconfigured for selectively receiving, storing and partitioning theaggregated accounting measures from said translation module into saidplurality of sections in real-time; and an accounting module coupled tosaid production model accounting database, said accounting moduleconfigured to receive aggregated data from the production modeldatabase, to provide accounting and reporting functionality for themanufacturing process in real-time; wherein the accounting system isconfigured to move data along a hierarchically upward data path from thesensors, to the sub-plant accounting modules, to the production modelaccounting database, the accounting port, and to the accounting module.